Catalyst with improved activity/selectivity for light naphtha aromatization

ABSTRACT

In an embodiment, a method for making a catalyst, comprises: forming a mixture comprising a germanium source, an alkali metal source, an aluminum source, and a silica source, wherein the mixture has a pH; adjusting the pH of the mixture to a value of greater than or equal to 9.5; crystallizing and calcining the mixture to form a zeolite; depositing platinum on the zeolite; and calcining the zeolite to form the final catalyst. The final catalyst is non-acidic and has an aluminum content of less than or equal to 0.75 wt % based on the total weight of the final catalyst excluding any binder and extrusion aide and a Si:Al2 mole ratio of greater than or equal to 125.

BACKGROUND

Zeolite is a crystalline hydrated aluminosilicate that can contain othermetals in the framework of the zeolite crystal or that can be deposited,exchanged, or impregnated on the zeolite (i.e. on the surface or in thepores). A method for preparing a zeolite comprises: preparing an aqueousmixture of silicon oxide and sources of oxides of aluminum; andmaintaining said aqueous mixture under crystallization conditions untilcrystals of zeolite form. In the crystalline structure, there are poresand channels that can be interconnected. The dimensions andconfiguration of these pores and channels allow access by molecules ofcertain sizes. Zeolites are used as catalysts for, among other things,isomerization, toluene disproportionation, transalkylation,hydrogenation, alkane oligomerization, and aromatization. Aromatizationis a multi-step process that can comprise the steps of dehydrogenationof the hydrocarbon, cyclization of the dehydrogenated hydrocarbon, andaromatization of the cyclized hydrocarbon.

One such example of hydrocarbon aromatization is aromatization ofnaphtha. Naphtha is a mixture mainly of straight-chained, branched, andcyclic aliphatic hydrocarbons, light naphtha having from five to ninecarbon atoms per molecule, and heavy naphtha having from seven to twelvecarbon atoms per molecule. Typically, light naphtha contains naphthenes,such as cyclohexane and methylcyclopentane, and linear and branchedparaffins, such as hexane and pentane. Light naphtha typically contains60 to 99 weight percent (wt %) of paraffins and cycloparaffins. Lightnaphtha can be characterized as a petroleum distillate having amolecular weight range of 70 to 150 gram per mole (g/mol), a specificgravity range of 0.6 to 0.9 grams per cubic centimeter (g/cm³), aboiling point range of 50 to 320 degree Fahrenheit (° F.) (10 to 160degree Celsius (° C.)), and a vapor pressure of 5 to 500 millimeter ofmercury (mmHg) at room temperature. Light naphtha can be obtained fromcrude oil, natural gas condensate, or other hydrocarbons streams by avariety of processes, e.g., distillation.

A zeolite with one or both of improved selectivity and conversion fornaphtha aromatization is desirable.

BRIEF SUMMARY

Disclosed herein is a catalyst, methods for making and using the same.

In an embodiment, a method for making a catalyst, comprises: forming amixture comprising a germanium source, an alkali metal source, analuminum source, and a silica source, wherein the mixture has a pH;adjusting the pH of the mixture to a value of greater than or equal to9.5; crystallizing and calcining the mixture to form a zeolite;depositing platinum on the zeolite; and calcining the zeolite to formthe final catalyst. The final catalyst is non-acidic and has an aluminumcontent of less than or equal to 0.75 wt % based on the total weight ofthe final catalyst excluding any binder and extrusion aide and a Si:Al₂mole ratio of greater than or equal to 125.

In another embodiment: a catalyst comprises: a zeolite comprising Si,Al, and Ge in the framework with Pt deposited thereon; wherein thecatalyst has an Si:Al₂ mole ratio of greater than or equal to 125, anSi:Ge mole ratio of 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5,wherein the catalyst has an aluminum content of less than or equal to0.75 wt %, wherein the catalyst is non-acidic.

In another embodiment: a method for the aromatization of hydrocarbonscomprises: contacting an alkane containing 6 to 12 carbon atoms permolecule with a catalyst comprising: a zeolite comprising Si, Al, and Gein the framework with Pt deposited thereon; wherein the catalyst has anSi:Al₂ mole ratio of greater than or equal to 125, an Si:Ge mole ratioof 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5, wherein thecatalyst has an aluminum content of less than or equal to 0.75 wt %excluding any binder and extrusion aide.

The above described and other features are exemplified by the followingdetailed description.

DETAILED DESCRIPTION

In previous methods of preparing a non-acidic catalyst for light naphthaaromatization, a mixture comprising an aluminum source, a silica source,a tetravalent metal, a trivalent metal, or a combination comprising oneor more of the foregoing was formed and the pH of the mixture was thenadjusted to a low pH of less than or equal to 9 (e.g., in order toobtain the desired amount of tetravalent metal on the catalyst).Materials prepared in this manner are generally acidic. An acidiczeolite catalyst has a number of sites with significant Brønsted orLewis acidity, and these sites promote cracking of feed components, anundesirable reaction in light naphtha aromatization. Hence, the catalystis generally subjected to a post-synthesis ion-exchange step where analkali metal or other basic component is used to neutralize the acidsites by bringing the alkali metal in close proximity to the aluminum.When alkali metals, which have a charge of +1, are used, the molar ratioof alkali metal to aluminum in the resulting non-acidic catalyst will begreater than 0.90, e.g., greater than or equal to 0.95. It wassurprisingly discovered that a non-acidic catalyst could be formed froma mixture having a pH value of greater than or equal to 9.5. Not to bebound by theory, it is believed that under such conditions, an increasedamount of sodium is present to neutralize the aluminum. It was furthersurprisingly discovered that although preparing the catalyst at thisincreased pH can limit the amount of germanium that can be incorporatedinto the final catalyst, for example, to less than 3 wt % based on thefinal weight of the catalyst (excluding any binder and extrusion aide),good activity and good selectivity can still be achieved. Good activityis a conversion of greater than or equal to 20% at a temperature of 515°C. and a liquid hourly space velocity of 8.6 reciprocal hours (hr⁻¹),preferably, greater than or equal to 30% and good selectivity is aselectivity of greater than or equal to 85%, preferably, greater than orequal to 90%.

The catalyst can be a germanium (Ge) substituted medium pore zeolite,onto which a noble metal (such as platinum) has been deposited.Preferably, the catalyst can be a non-acidic, low aluminum Pt/Ge-ZSM-5catalyst, e.g., having an amount of aluminum (Al) of less than or equalto 0.75 wt %, for example, 0.45 to 0.7 wt %, based upon a total weightof the final catalyst. As used here, a non-acidic zeolite refers to anon-acidic zeolite that has substantially all of its cationic sites ofexchange, e.g., those typically associated with aluminum, occupied bynon-hydrogen cationic species, e.g., alkali or alkaline earth metalssuch as sodium, potassium, rubidium, cesium, lithium, magnesium,calcium, barium, or a combination comprising one or more of theforegoing; preferably, the alkali metal can comprise sodium. Thecationic sites are often responsible for cracking of hydrocarbons intoundesired products.

The zeolite can be any of a number of zeolites, where zeolites arecrystalline aluminosilicates with a three-dimensional frameworkcontaining silica (SiO₄) and alumina (AlO₄) tetrahedra and can benaturally occurring or synthesized. Zeolite can contain elements otherthan aluminum and silicon in the crystalline framework. The term“zeolite” includes not only aluminosilicates, but substances in whichthe aluminum is replaced by other trivalent elements, and substances inwhich silicon is replaced by other tetravalent elements. Zeolites areknown catalysts for isomerization, toluene disproportionation,transalkylation, hydrogenation and alkane oligomerization andaromatization. Some zeolite catalysts, especially those containing aGroup VIII deposited metal, can be susceptible to sulfur poisoning.

Examples of the zeolite structure are MTW, FER, MEL, TON, MRE, MWW, MFI,BEA, MOR, LTL, or MTT. The term “ZSM-5” is used in this specification tomean a zeolite having an MFI structure. The zeolite can comprise ZSM-5,ZSM-11, ZSM-23, ferrierite, mordenite, or a combination comprising oneor more of the foregoing. The zeolite can be from a family of pentasilzeolites that contain five membered ring units or pentasil units in theframework structure. Such zeolites include ZSM-5, ZSM-11, ZSM-23, and soon. The zeolite can be ZSM-5 or MFI (International Zeolite Associationnomenclature of ZSM-5). The ZSM-5 zeolite has a two-dimensional porestructure with straight channels (5.4 Angstroms (Å)×5.6 Å) which areintersected by sinusoidal channels (5.1 Å×5.7 Å) with a maximum diameterof 9 Å at the intersection. The ZSM-5 zeolite catalysts and theirpreparation are described, for example, in U.S. Pat. No. 3,702,886. SuchZSM-5 zeolites are aluminosilicates that contain both silicon andaluminum in the crystalline structure. ZSM-11 is another pentasilaluminosilicate zeolite that is similar to ZSM-5.

The zeolite can contain elements other than aluminum and silicon in thecrystalline framework, where at least some of the aluminum can bereplaced by other trivalent elements and/or at least some of the siliconcan be replaced by other tetravalent elements. Generally, zeolites arestructures of TO₄ tetrahedra, which form a three dimensional network bysharing oxygen atoms where T represents tetravalent elements, such assilicon, and trivalent elements, such as aluminum. Tetravalent elements,such as germanium, tin, lead, zirconium, titanium, vanadium, orchromium, can be substituted for the silicon. Trivalent elements such asgallium, boron, indium, thallium, or iron, can be substituted for thealuminum. These tetravalent and trivalent elements would be in theframework of the zeolite crystal, also referred to as frameworkelements. Other elements which can be in the framework of the zeolitecrystal are zinc and/or phosphorus.

A germanium zeolite includes silicon, germanium, and optionally aluminumin the crystalline framework of the zeolite structure, for example, agermanium zeolite can be an aluminosilicate zeolite having germanium inthe framework and can preferably be a germanium ZSM-5 (Ge-ZSM-5)zeolite. A germanium zeolite can comprise a medium pore zeolite havingan average pore size of 5 to 8 Å, a silica to alumina mole ratio (“SAR”;also referred to as Si:Al₂ mole ratio) of 125 to 200, and a germaniumcontent of 0.1 to 3 wt %, preferably, 0.3 to 3 wt % based on the totalweight of the final catalyst (excluding binder and extrusion aide). Agermanium zeolite can comprise a zeolite having a structure such as MTW,FER, MEL, TON, MRE, MWW, MFI, BEA, MOR, LTL, and MTT.

The zeolite can be formed by preparing a mixture, allowing the mixtureto form a gel, and crystallizing the zeolite therefrom. The mixture cancomprise an aqueous solution of a germanium source (such as germaniumdioxide), a sodium source (e.g., NaOH and/or NaCl), and an aluminumsource (such as sodium aluminate, e.g., a sodium aluminate solutioncomprising alumina and sodium oxide), e.g., as a single aqueous solutionor multiple solutions that are combined. For example, the zeolite can beformed by preparing two aqueous solutions, the first solution comprisinga germanium source and a sodium source, and the second solutioncomprising an aluminum source, and combining said solutions. The mixturecan comprise a silica source such as an ammonium or sodium ionstabilized colloidal silica, e.g. Ludox™ AS-30, Ludox™ AS-40, Ludox™SM-30, Ludox™ HS-30, commercially available from Sigma-Aldrich, orNalco™ 1034A, Nalco™ 2326, Nalco™ 2327, Nalco™ 2329, Nalco™ DVSZN002,commercially available from Nalco, wherein the colloidal silica can, forexample, comprise 15 to 40 wt % silica, based upon a total weight ofcolloidal material.

The mixture can comprise an organic structure directing agent, which isincorporated in the microporous space of the crystalline network duringcrystallization, thus controlling the construction of the network andassisting to stabilize the structure through the interactions with, forexample, the silicon and aluminum. Examples of the structure directingagent are organic amine and quaternary ammonium compounds and salts andcations thereof. Specifically, the structure directing agent cancomprise tetra n-propyl ammonium hydroxide, tetra n-propyl ammoniumbromide, tetra n-propyl ammonium chloride, tetraethyl ammoniumhydroxide, tetraethylammonium bromide, tetramethylammonium chloride,hexamethyleneimine, 1,4-di(1′4′-diazabicyclo[2.2.2]octane)butanehydroxide, morpholine, cyclohexylamine, diethylethanolamine,N,N′-diisopropyl imidazolium cation, tetrabutylammonium compounds,di-n-propylamine (DPA), tripropylamine, triethylamine (TEA),triethanolamine, piperidine, 2-methylpyridine, N,N-dimethylbenzylamine,N,N-diethylethanolamine, dicyclohexylamine, N,N-dimethylethanolamine,choline cation, N,N′-dimethylpiperazine, 1,4-diazabicyclo(2,2,2)octane,1,6-hexanediamine, N′,N′,N,N-tetramethyl-(1,6)hexanediamine,N-methyldiethanolamine, N-methyl-ethanolamine, N-methyl piperidine,3-methyl-piperidine, N-methylcyclohexylamine, 3-methylpyridine,4-methyl-pyridine, quinuclidine,N,N′-dimethyl-1,4-diazabicyclo(2,2,2)octane ion; di-n-butylamine,neopentylamine, di-n-pentylamine, isopropylamine, t-butyl-amine,ethylenediamine, pyrrolidine, 2-imidazolidone, aN-benzyl-1,4-diazabicyclo[2.2.2]octane cation, a1-[1-(4-chlorophenyl)-cyclopropylmethyl]-1-ethyl-pyrrolidinium cation, a1-ethyl-1-(1-phenyl-cyclopropylmethyl)-pyrrolidium cation, and1,8-diaminooctane. The mixture can comprise a combination comprising oneor more of the foregoing structure directing agents. The structuredirecting agent can comprise tetra-n-propyl ammonium hydroxide (TPAOH)).The mixture can have a structure directing agent to silica mole ratio of0.01 to 1, preferably, 0.05 to 0.5.

The Si:Al₂ mole ratio of the mixture can be 175 to 290, preferably, 200to 275, more preferably, 220 to 275. The Si:Ge mole ratio in the mixturecan be 5 to 100, preferably, 15 to 50. The Na:Al mole ratio in themixture can be 10 to 60, preferably, 12 to 40. The pH of the mixture canbe adjusted to a value of greater than 9, preferably, greater than orequal to 10, more preferably, 10 to less than or equal to 13. Forexample, the pH of the mixture can be adjusted to a value of greaterthan or equal to 9.5, preferably, 9.5 to 12.5, more preferably, 10 to12.5.

It is noted that although some zeolites are prepared with fluoride as asynthesis aid, this can be undesirable due to the potential hightoxicity and corrosivity of fluoride, which can render it difficult andimpractical to use in a commercial synthesis. Accordingly, the processdisclosed herein can be fluoride free and hence, the final zeolite canbe fluoride free (i.e., besides possible impurities, the zeolite has nofluoride). In other words, no fluoride is intentionally added during theprocess.

The mixture can then be crystallized, washed, and then calcined, to formthe zeolite. The crystallization can occur at a temperature of 140 to200° C., preferably, 160 to 180° C. The crystallization can occur for atime of up 6 days, preferably, 1 to 6 days, more preferably, 1.5 to 5days. The crystallized zeolite can be washed with water and calcined.The zeolite can be calcined, e.g., to burn off one or more of thezeolite structure directing agents and any other decomposable materialsthat may be present. The zeolite can be calcined at a temperature ofgreater than or equal to 500° C., preferably, greater than or equal to530° C., more preferably, greater than or equal to 550° C. The zeolitecan be calcined at a temperature of 500 to 650° C. The zeolite can becalcined for greater than or equal to 0.5 hours (hr), preferably,greater than or equal to 1 hr, more preferably, greater than or equal to2 hr. The zeolite can be calcined for 0.5 to 20 hr.

A noble metal can be deposited on the calcined zeolite, for example, bymethods such as ion exchange, impregnation, and incipient wetnessimpregnation. The noble metal can be added to the calcined zeolite as anoble metal compound (e.g., a noble metal salt) that readily dissolvesin water. For example, when the metal is platinum, the platinum sourcecan be any applicable platinum source, such as chloroplatinic acid(H₂PtCl₆—6H₂O), tetraamine platinum nitrate ((NH₂)₄Pt(NO₃)₂), or acombination comprising at least one of the foregoing. The noble metalcan be present in the final catalyst in a reduced amount of less than orequal to 3.0 wt % (as measured by x-ray fluorescence (XRF) technique),preferably, 0.05 to 3.0 wt %, more preferably, 0.25 to 3 wt %, morepreferably, 0.2 to 2 wt %, even more preferably, 0.2 to 1.5 wt % basedon the total weight of the catalyst (excluding binder and extrusionaide). The noble metal can comprise palladium, silver, platinum, gold,iridium, rhodium, ruthenium, or a combination comprising one or more ofthe foregoing, preferably, the noble metal can comprise platinum. Thenoble metal, such as platinum, can be deposited on the crystallinestructure before or after the addition of the binder and shaping of thezeolite. After the noble metal has been added, the zeolite can be againheated, e.g., to about 300° C.

The method of making the present catalyst can be free of an ion-exchangestep, for example, ion-exchange with an alkali metal, for example,cesium compound.

The zeolite can be heat treated after one or both of ion-exchanging witha base and after noble metal deposition to form the final catalyst. Thecatalyst can be heated at an elevated temperature of greater than orequal to 200° C., preferably, 200 to 400° C. for a period of timesufficient to decompose the metal salt(s). The heating time can be 0.5to 10 hr, preferably, 0.5 to 5 hr. The catalyst can be further calcined,e.g., at a temperature of 200 to 400° C., preferably, 250 to 330° C.,for a period of 0.5 to 20 hr, preferably, 1 to 20 hr, more preferably, 5to 8 hr. The heat treatment and/or calcination can be under air, O₂, N₂,H₂ or a combination comprising at least one of the foregoing.

The final catalyst can be non-acidic. The final catalyst can have an SARof greater than or equal to 125, preferably, 125 to 200, morepreferably, 140 to 190. The final catalyst can have an Si:Ge mole ratioof 40 to 400, preferably, 50 to 300, more preferably, 80 to 200. Thefinal catalyst can have an Na:Al mole ratio of 0.9 to 2.5, preferably,1.2 to 2.2. The final catalyst can have a germanium content of 0.3 to 3wt %, preferably, 0.4 to 2.5 wt %, more preferably, 0.6 to 1.5 wt %,even more preferably, 0.5 to 1.5 wt %, based upon a total weight of thefinal catalyst (excluding binder). The final catalyst can comprise oneor more of 0.5 to 2 wt %, preferably, 1 to 2 wt % Na; less than or equalto 0.75 wt %, preferably, less than or equal to 0.7 wt %, morepreferably, 0.4 to 0.7 wt % Al; less than 3 wt %, preferably, less thanor equal to 2.5 wt %, more preferably, 0.4 to 1.5 wt % Ge; 0.05 to 3 wt%, preferably, 0.2 to 2 wt %, more preferably, 0.2 to 1.5 wt % Pt; or acombination comprising one or more of the foregoing; based upon a totalweight of the final catalyst (excluding binder). The final catalyst canbe free of cesium, for example, can comprise less than or equal to 0.1wt %, for example, 0 wt % of cesium based on the total weight of thecatalyst (excluding binder).

The chemical formula of the final catalyst can be represented by theformula I:

Pt_(z)[(0.9-2.5)M⁺ _(y)(SiO₂)(GeO₂)_(x)(AlO₂)_(y)]  (I)

wherein z is 0.00015 to 0.01; M⁺ is an alkali metal, such as sodium, yis 0 to 0.02, preferably, 0.01 to 0.017; and x is 0.0025 to 0.025,preferably, 0.003 to 0.0125.

An additive can be added to the catalyst, which can comprise a binderand/or an extrusion aid to form a forming mixture. The binder cancomprise inorganic oxide materials. The binder can comprise an aluminum-or silicon-containing material such as silica, alumina, clay, aluminumphosphate, silica-alumina, or combinations comprising at least one ofthe foregoing. The binder can comprise oxides of magnesium, titanium,zirconium, thorium, silicon, boron, and mixtures thereof; a clay, e.g.,kaolin or montmorillonite; carbon, e.g., carbon black, graphite,activated carbon, polymers or charcoal; a metal carbide or nitride,e.g., molybdenum carbide, silicon carbide or tungsten nitride; a metaloxide hydroxide, e.g., boehmite; or a combination comprising one or moreof the foregoing. The binder can comprise 0.5 to 30 wt %, preferably, 1to less than 10 wt %, more preferably, 1 to 4.5 wt % non-silica oxides,based upon the total weight of the forming mixture.

The binder can comprise a colloidal silica binder, where the colloidalsilica binders are acid, NH₄ ⁺, or Na⁺ stabilized colloidal silicas. Thebinder can comprise a solid silica that can comprise a crystallinesilica, an amorphous silica, or a combination thereof. The binder cancomprise at least one colloidal silica binder and at least one solidsilica (SiO₂) binder. Some examples of solid silica binders includeattapulgite, e.g. Min-U-Gel™ commercially available from Active MineralsInternational, Ultrasil™ commercially available from Sigma-Aldrich,those available from Degussa Corporation, and Davisil™-643 commerciallyavailable from Sigma-Aldrich.

The binder can have an average particle size of 10 to 25 nanometer (nm)based on a major axis. The binder can comprise a mixture of one or morebinders and can comprise at least one solid binder and a mixture ofcolloidal binders, the mixtures of colloidal binders including at least10 wt % of a colloidal binder having an average particle size of 10 to30 nm based on a major axis, while the remaining colloidal binders canhave an average particle size of 1 to 30 nm based on a major axis. Thebinder can comprise a mixture of at least 20 wt % of a colloidal binderhaving an average particle size of 10 to 30 nm based on a major axis,while the remaining binders can have an average particle size of 5 to 10nm based on a major axis. The binder can have a surface area less thanor equal to 250 meter square per gram (m²/g), preferably, 250 to 100m²/g.

The binder can be present in the catalyst in an amount of up to 99 wt %,e.g., 1 to 99 wt %, preferably, 10 to 60 wt % based on the total weightof the forming mixture. The catalyst can comprise 15 to 50 wt %,preferably, 20 to 40 wt % of silica-containing binder material, morepreferably, 20 to 30 wt %, based upon a total weight of the formingmixture.

The extrusion aid can comprise polyvinyl alcohol and/or polyacrylamide.For example, the extrusion aid can comprise a partially hydrolyzedpoly(vinyl alcohol), e.g., produced commercially by hydrolysis ofpoly(vinyl acetate). When poly(vinyl acetate) is hydrolyzed the acetategroups (COCH₃) are substituted by hydrogen to form alcohol (OH) groupsalong the polymer chain. Hereinafter, the term ‘partially hydrolyzed’refers to a poly(vinyl acetate) that has been hydrolyzed by less than orequal to 90%. In the partially hydrolyzed poly(vinyl alcohol), acetateand alcohol groups are randomly distributed in the polymer chain. Thepartially hydrolyzed poly(vinyl alcohol) can have a weight averagemolecular weight (Mw) (for example, based on polycarbonate standards) of500 to 500,000 g/mol, preferably, 10,000 to 200,000 g/mol. The partiallyhydrolyzed poly(vinyl alcohol) can be used in an amount of 0.1 to 5 wt%, preferably, 0.5 to 3 wt %, more preferably, 1 to 2 wt %, based on thetotal weight of the forming mixture.

The extrusion aid can comprise polyacrylamide. The polyacrylamide canhave a weight average molecular weight (Mw) of 2 to 10 million g/mol,preferably, 2 to 7 million g/mol as determined by gel permeationchromatography based on polycarbonate standard. The polyacrylamide canbe used in an amount of 0.1 to 5 wt %, preferably, 0.5 to 3 wt %, morepreferably, 1 to 2 wt %, based on the total weight of the formingmixture. An example of a commercially available source of polyacrylamideis sold as under the trademark CYFLOC™ N-300 LMW Flocculant availablefrom Cytec, West Peterson, N.J., which is a polyacrylamide having a Mwof 2 to 5 million g/mol as determined by gel permeation chromatographybased on polycarbonate standard.

The forming mixture can be shaped (also referred to as formed) to resultin a formed catalyst. The formed catalyst can be shaped by variousforming processes such as pelletizing, tableting, extruding, and anyother technique of forming a catalyst into a shape, as well as acombination comprising at least one of the foregoing processes. Theresulting formed catalyst can be, for example, pellets or tablets. Theformed catalyst can have cross-sections that are, for example, circular,oval, oblong, square, rectangular, diamond, polygonal, or a combinationcomprising one or more of the foregoing. Specific examples are 1/16 inch(1.6 millimeter (mm)) to ⅛ inch (3.2 mm) cylindrically shapedextrudates.

The catalyst can concurrently function as one or more of, adehydrogenation, a dehydrocyclization, and an aromatization catalyst.Preferably, the catalyst can be used in a process of aromatization ofalkanes, such as alkanes having six to twelve carbon atoms (C₆₋₁₂) permolecule, to produce aromatics, such as benzene, ethyl benzene, toluene,and xylenes. The contact between the alkane and the catalyst can be at aliquid hourly space velocity of 0.1 to 100 hr⁻¹, at a temperature of 200to 950° C., preferably, 425 to 650° C., more preferably, 450 to 600° C.,even more preferably, 475 to 550° C., at a pressure of 5 to 315 poundsper square inch absolute (psia). The present catalyst can work with abroad range of feeds, including paraffinic and olefinic compounds and/ornaphthenes. For example, the feedstream to the reactor comprising thecatalyst may comprise greater than or equal to 30 volume percent (vol %)paraffins (e.g., greater than or equal to 50 volume percent (vol %)paraffins), and optionally low, (i.e. less than or equal to 20 vol %, oreven less than or equal to 10 vol %) naphthenes. The feedstream cancomprise C₆₋₈ alkanes, either alone or as components in a mixture, i.e.,in an amount of 0 to 100 vol % (e.g., greater than 0 up to 100 wt %, orgreater than or equal to 10 wt %, preferably, greater than or equal to20 wt %) for each of C₆, C₇, and C₈ alkane.

The feedstream can be a naphtha feed. The naphtha feed can be a refineryproduct comprising greater than or equal to 25 wt %, preferably, greaterthan or equal to 35 wt %, more preferably, greater than or equal to 50wt % of C₅₋₉ aliphatic and cycloaliphatic hydrocarbons such as olefinsand paraffins, and zero to 40 wt % C₆₋₁₃ aromatics (e.g., greater thanzero to 40 wt % C₆₋₁₃ aromatics). The naphtha feed can comprise up to1,000 parts per million by weight (ppm) sulfur, preferably, 1 to 500 ppmsulfur, more preferably, 1 to 200 ppm sulfur, even more preferably, 1 to50 ppm sulfur, where the term sulfur refers to elemental sulfur as wellas sulfur compounds (such as organosulfides and heterocyclicbenzothiophenes). The naphtha feed can comprise up to 100 parts permillion by weight (ppm) of nitrogen compounds.

The following examples are provided to illustrate the improved catalyst.The examples are merely illustrative and are not intended to limitdevices made in accordance with the disclosure to the materials,conditions, or process parameters set forth therein.

EXAMPLES

The materials used in the following examples are described in Table 1.Unless specifically, stated otherwise, the materials are used in theform as set forth in Table 1, and the quantities identified in theexamples are based upon that form.

TABLE 1 Component Source Sodium hydroxide (NaOH) 50 wt % aqueoussolution Sigma-Aldrich Germanium dioxide Umicore Sodium aluminatesolution Southern Ionics Tetra-n-amine platinum nitrate ((NH₃)₄Pt(NO₃)₂,Sigma-Aldrich 49.9 wt % Pt) Tetra-n-propyl aluminum hydroxide (TPAOH);SACHEM Nalco 2326 (15 wt % silica in a colloidal state) Nalco CompanyGlacial acetic acid Sigma-Aldrich Cesium nitrate (CsNO₃) Cabot SpecialtyFluids

The following procedure was used to synthesize the catalysts used inExamples 1-21, where the amounts were varied according to the specificexample and where the amounts in the final catalysts are shown in thecorresponding tables; the specific numbers shown in the procedure arefor Example 1. Solution 1 was made by diluting a 50 wt % NaOH solutionwith deionized water and subsequently dissolving in germanium dioxide.Solution 2 was made by diluting a sodium aluminate solution (23.6 wt %alumina and 19.4 wt % sodium oxide) with deionized water. The twosolutions were combined and mixed. TPAOH was added and stirred for about10 minutes (min). Ludox AS-40 was added all at once and the gel wasstirred for 2.5 hours (hr) to make it homogeneous. Glacial acetic acidwas added as needed to adjust the pH of the mixture.

The gel was loaded into a 1 liter (L) stainless steel autoclave andheated at 160° C. for 3 days with stirring. The solids were thenfiltered from the mother liquor and washed with deionized water. Thesolid was calcined at 550° C. for 10 hr in an oven with air flow toresult in a Ge-ZSM-5 zeolite. The MFI structure of the solid wasconfirmed by measuring the powder X-ray diffraction pattern.

Where the final catalyst comprises platinum, incipient wetnessimpregnation was carried out by adding, dropwise, a solution oftetraammineplatinum nitrate dissolved in deionized water to the Ge-ZSM-5zeolite. The material was dried for 1 hr at 110° C. in an oven and thencalcined at 280° C. for 3 hr. Elemental analysis for each catalyst isshown in the corresponding tables.

The catalyst powder was pressed and sized to 20-40 mesh. 0.25 cubiccentimeters (cm³) (0.131 grams (g)) of the sized catalyst was mixed with1.75 cm³ of inert silicon carbide chips and was heated at 460° C. for 1hr in flowing H₂. The temperature was then raised to 515° C. andcatalytic testing, where performed, was started. A gas mixture wasformed by vaporizing n-hexane into a stream of flowing hydrogen at atemperature of approximately 150° C. This gas mixture was passed throughthe reactor, which was maintained at 515° C. by an external heatingjacket. The reaction products were analyzed by gas chromatography.Products ranging in size from methane to dimethylnaphthalene wereobserved. For the purposes of calculating conversion and selectivity, C₆isomerization and dehydrogenation products were considered to beunreacted. The selectivities, S₅₀ (i.e., catalyst selectivity after 50hours on stream) reported were calculated as the sum of benzene,toluene, and xylenes (BTX) produced divided by the sum of benzene andall C₁₋₅ and C₇₊ materials recovered. These selectivities are presentedon a molar C₆ basis. The conversions, X₅₀ (i.e., catalyst activity after50 hours on stream), reported were calculated as the fraction ofn-hexane feed converted to benzene, toluene, xylenes, and all C₁₋₅ andC₇₊ materials recovered.

Table 2 summarizes the synthesis data for Example 1 and shows that thismaterial has excellent catalytic performance, with a conversion of 31%and an aromatics selectivity of 96% at the conditions described above.The weight percent values of the respective components are based on thetotal weight of the final catalyst.

Examples 2-7 Varying the Si:Al₂ Mole Ratio

Six catalysts as shown in Examples 2-7 were made and tested forconversion and selectivity, where the Si:Al₂ mole ratio in the mixturewas varied. Specifically, the process was the same as set forth forExample 1 except that the synthesis mixtures used in Examples 2-7 hadSi:Al₂ mole ratios of 110, 170, 225, 250, 275, and 300, respectively.Correspondingly, the Si:Al₂ mole ratios in the final catalyst ofExamples 2-7 were 60, 102, 151, 178, 189, and 206, respectively. Theresults are shown in Table 3.

TABLE 2 Example 1 Mixture composition SiO₂:Al₂O₃ (mole ratio) 225 Na:Al(mole ratio) 11.23 Na₂O:SiO₂ (mole ratio) 0.05 TPAOH:SiO₂ 0.10 (moleratio) H₂O:SiO₂ (mole ratio) 23 SiO₂:Ge (mole ratio) 30 OH⁻:SiO₂ (moleratio) 0.20 pH 12.0 Final catalyst composition SiO₂:Al₂O₃ (molar ratio)195 Na (wt %) 0.74 Si (wt %) 43.94 Al (wt %) 0.45 Ge (wt %) 1.11 Cs (wt%) 0 Pt (wt %) 1.03 Catalytic performance X₅₀ 31 S₅₀ 96

TABLE 3 Example 2 3 4 5 6 7 Mixture composition Si:Al₂ 110 170 225 250275 300 (mole ratio) Na:Al 24.71 24.71 24.71 27.5 30.25 24.72 (moleratio) Si:Ge 29.83 29.84 29.84 29.83 29.84 29.84 (mole ratio) TPAOH:SiO₂0.10 0.10 0.10 0.10 0.10 0.14 (mole ratio) H₂O:SiO₂ 23.85 23.85 23.8523.85 23.85 24.50 (mole ratio) pH 12.0 12.1 12.0 12.2 12.4 12.1 Finalcatalyst composition Si:Al₂ 60 102 151 178 189 206 (mole ratio) Na:Al0.79 1.01 1.64 2.10 2.48 2.65 (mole ratio) Si:Ge 243 280 193 186 168 178(mole ratio) Na (wt %) 0.93 0.74 0.81 0.86 0.95 0.97 Si (wt %) 43.0845.27 45.47 44.39 44.11 45.87 Al (wt %) 1.39 0.86 0.58 0.48 0.45 0.43 Ge(wt %) 0.46 0.42 0.61 0.62 0.68 0.67 Catalytic performance X₅₀ 8 28 3323 31 2 S₅₀ 70 84 94 96 96 73

Table 3 shows that improved conversion and selectivity are observed whenthe Si:Al₂ mole ratio in the final catalyst is 151 to 189, where Example4, 5, and 6 resulted in conversions of 33%, 23%, and 31%, respectively,and selectivities of 94%, 96%, and 96%, respectively.

Examples 8-11 Varying the Si:Ge Mole Ratio

Four catalysts as shown in Examples 8-11 were made and tested forconversion and selectivity, where the Si:Ge mole ratio in the mixturewas varied. Specifically, the synthesis mixtures used in Examples 8-11had Si:Ge mole ratios of 15, 22, 29.8, and 50, respectively.Correspondingly, the Si:Ge mole ratios in the final catalyst of Examples8-11 were 88, 141, 193, and 287, respectively. The results are shown inTable 4.

TABLE 4 Example 8 9 10 11 Mixture composition Si:Al₂ (mole ratio) 225225 225 225 Na:Al (mole ratio) 24.69 24.69 24.71 24.71 Si:Ge (moleratio) 15 22 29.8 50 TPAOH:SiO₂ 0.10 0.10 0.10 0.10 (mole ratio)H₂O:SiO₂ (mole ratio) 23.85 23.85 23.85 23.88 pH 12.0 12.0 12.0 12.0Final catalyst composition Si:Al₂ (mole ratio) 168 159 151 139 Na:Al(mole ratio) 1.82 1.72 1.64 1.98 Si:Ge (mole ratio) 88 141 193 287 Na(wt %) 0.79 0.79 0.81 1.06 Si (wt %) 44.50 44.64 45.47 45.42 Al (wt %)0.51 0.54 0.58 0.63 Ge (wt %) 1.31 0.82 0.61 0.41 Catalytic performanceX₅₀ 36 33 33 24 S₅₀ 94 94 94 95

Table 4 shows that over all the Si:Ge mole ratios tested, the catalystsof Examples 8-11 displayed high conversions of 24 to 36% and highselectivities of 94 to 95%.

Examples 12-16 Varying the pH of the Mixture

Five catalysts as shown in Examples 12-16 were made and tested forconversion and selectivity, where the pH of the mixture was varied.Specifically, the pH values of the mixtures of Examples 12-16 were 9.1,10.0, 11.0, 12.0, and 13.0, respectively. The results are shown in Table5.

TABLE 5 Example 12 13 14 15 16 Mixture composition Si:Al₂ (mole ratio)225 225 225 225 225 Na:Al (mole ratio) 24.68 24.71 24.71 24.71 24.69Si:Ge (mole ratio) 29.84 29.84 29.84 29.84 29.84 TPAOH:SiO₂ 0.10 0.100.10 0.10 0.42 (mole ratio) H₂O:SiO₂ (mole ratio) 23.85 23.85 23.8523.85 28.55 pH 9.1 10.0 11.0 12.0 13.0 Final catalyst composition Si:Al₂(mole ratio) 204 211 177 151 106 Na:Al (mole ratio) 0.28 1.69 1.92 1.640.79 Si:Ge (mole ratio) 42 49 92 193 466 Na (wt %) 0.10 0.59 0.80 0.810.55 Si (wt %) 44.36 44.90 44.90 45.47 44.89 Al (wt %) 0.42 0.41 0.490.58 0.82 Ge (wt %) 2.74 2.40 1.27 0.61 0.25 Catalytic performance X₅₀ 327 23 33 16 S₅₀ 53 92 94 94 77

TABLE 6 Example 17 18 19 20 21 Mixture composition Si:Al₂ (mole ratio)225 225 225 225 225 Na:Al (mole ratio) 6.97 13.35 24.71 40.0 45.0 Si:Ge(mole ratio) 29.84 29.84 29.84 29.84 29.84 TPAOH:SiO₂ 0.12 0.13 0.100.12 0.10 (mole ratio) H₂O:SiO₂ (mole ratio) 23.73 24.11 23.85 24.0923.85 pH 12.1 12.1 12.0 12.1 12.1 Final catalyst composition Si:Al₂(mole ratio) 69 177 151 141 126 Na:Al (mole ratio) 0.32 2.10 1.64 1.731.62 Si:Ge (mole ratio) 106 139 193 141 288 Na (wt %) 0.34 0.86 0.810.90 0.94 Si (wt %) 44.94 43.93 45.47 44.55 44.48 Al (wt %) 1.26 0.480.58 0.61 0.68 Ge (wt %) 1.10 0.82 0.61 0.82 0.40 Catalytic performanceX₅₀ 19 39 33 36 47 S₅₀ 7 93 94 95 91

Table 5 shows that improved conversion and selectivity are observed whenthe pH of the mixture is greater than 9.5, preferably, 10 to 12, whereExamples 13-15 resulted in conversions of 27%, 23%, and 33%,respectively, and selectivities of 92%, 94%, and 94%, respectively.

Examples 17-21

Varying the Na:Al Mole Ratio

Five catalysts as shown in Examples 17-21 were made and tested forconversion and selectivity, where the Na:Al mole ratio in the mixturewas varied. Specifically, Examples 17-21 had Na:Al mole ratios of 6.97,13.35, 24.71, 40.0, and 45.0, respectively. Correspondingly, the Na:Almole ratios in the final catalyst of Examples 17-21 were 0.32, 2.10,1.64, 1.73, and 1.62, respectively. The results are shown in Table 6.

Table 6 shows that improved conversion and selectivity are observed whenthe Na:Al mole ratio in the final catalyst is greater than 0.9, whereExamples 18, 19, 20, and 21 resulted in conversions of 39%, 33%, 36%,and 47%, respectively, and selectivities of 93%, 94%, 95%, and 91%,respectively.

Comparative Examples 22-23

Comparative Example 22 was prepared according to the procedure in U.S.Pat. No. 7,902,413, as follows: Solution #1 was made by diluting 15.84 gof 50 wt % NaOH solution with 131.25 g of deionized (DI) water andsubsequently dissolving 7.11 g of germanium dioxide. Solution #2 wasmade by diluting 3.84 g sodium aluminate solution (23.6 wt % alumina and19.4 wt % sodium oxide) with 153.9 g DI water. Solution #1 was added to150.0 g Ludox AS-40 (40 wt % silica in a colloidal state) and stirredfor 7 minutes. Solution #2 was added, and the resulting mixture wasstirred for 20 minutes. 105.42 g of tetra-n-propyl ammonium hydroxide(TPAOH) was added and the mixture was stirred for 60 minutes. Finally,23.34 g of glacial acetic acid was added to the mixture to adjust the pHto 9.2. This mixture was loaded into a 1 L stainless steel autoclave andheated at 160° C. for 36 hours with stirring. Subsequently, the solidsobtained were filtered from the mother liquor and washed with deionizedwater. The solid was calcined at 550° C. for 10 hours in an oven withair flow. The MFI structure of the solid was confirmed by measuring thepowder X-ray diffraction pattern.

A portion of the resulting Ge-ZSM-5 zeolite was ion-exchanged with anaqueous solution of CsNO₃ (0.5 M) in 4 steps at room temperature andthen filtered. The filtrate was then washed on filter with distilledwater and calcined for 3 hours at 280° C. in air. Incipient wetnessimpregnation was carried out by dropwise addition of a solution oftetraammineplatinum nitrate dissolved in deionized water to the Ge-ZSM-5zeolite. The material was dried at 90° C. in an oven and then calcinedat 280° C. for 3 hr.

Comparative Example 23 was prepared by the same procedure, except thatonly half as much sodium aluminate (1.92 g) was used. For this sample,23.0 g of acetic acid was required to adjust the pH to 9.2.

Comparative Examples 22 and 23 were tested according to the sameprocedures used for Examples 1-21. Results of elemental analysis andcatalyst testing are shown in Table 7.

TABLE 7 Example 22 23 Mixture composition Si:Al₂ (mole ratio) 112 225Na:Al (mole ratio) 12.49 23.65 Si:Ge (mole ratio) 14.69 14.69 TPAOH:SiO₂0.21 0.21 (mole ratio) H₂O:SiO₂ (mole ratio) 24.95 24.89 pH 9.22 9.15Final catalyst composition Si:Al₂ (mole ratio) 103 195 Cs:Al (moleratio) 1.17 1.76 Si:Ge (mole ratio) 25 18 Cs (wt %) 4.38 3.46 Si (wt %)40.60 40.48 Al (wt %) 0.76 0.40 Ge (wt %) 4.19 5.69 Catalyticperformance X₅₀ 20 3 S₅₀ 93 38

As can be seen in Table 7, Comparative Example 23, which was prepared atpH 9, contains a higher content of aluminum and germanium and has beenbase-exchanged with cesium, is less active and less selective thanExamples 4-6, 8-11, 14, 15, 19, and 20; Examples 13 and 18 have similarselectivity to Comparative Example 22 but have higher conversion.

As can be seen in Table 7, Comparative Example 23, which is prepared atpH 9 and with Cs-base exchange but with less aluminum, has anunacceptably low conversion and selectivity for n-hexane conversion.

Set forth below are some embodiments of the present catalyst and methodsof making and using the same.

Embodiment 1: a method for making a catalyst, comprising: forming amixture comprising a germanium source, an alkali metal source, analuminum source, and a silica source, wherein the mixture has a pH;adjusting the pH of the mixture to a value of greater than or equal to9.5, preferably, greater than 9.5; crystallizing and calcining themixture to form a zeolite; depositing platinum on the zeolite; andcalcining the zeolite to form the final catalyst. The final catalyst isnon-acidic and has an aluminum content of less than or equal to 0.75 wt% based on the total weight of the final catalyst excluding any binderand extrusion aide and a final Si:Al₂ mole ratio of greater than orequal to 125.

Embodiment 2: the method of Embodiment 1, further comprising allowingthe mixture to form a gel after adjusting the pH.

Embodiment 3: the method of any of Embodiments 1-2, wherein the formingof the mixture comprises: forming a first aqueous solution, wherein thefirst solution comprises the germanium source and the alkali metalsource; forming a second aqueous solution, wherein the second solutioncomprises the aluminum source; combining the first and second aqueoussolutions to form a combined solution; and adding the silica source tothe combined solution to form the mixture.

Embodiment 4: the method of any of Embodiments 1-3, wherein the mixturehas a mixture Si:Al₂ mole ratio of 175 to 290.

Embodiment 5: the method of any of Embodiments 1-4, wherein the mixturehas a mixture Si:Ge mole ratio of 5 to 100.

Embodiment 6: the method of any of Embodiments 1-5, wherein the mixturehas a Na:Al mole ratio of 10 to 60.

Embodiment 7: the method of any of Embodiments 1-6, wherein the mixturehas a mixture Si:Al₂ mole ratio of 175 to 290, a mixture Si:Ge moleratio of 5 to 100, and a mixture Na:Al mole ratio of 10 to 60.

Embodiment 8: the method of any of Embodiments 1-7, wherein the mixturehas a mixture Si:Al₂ mole ratio of 200 to 275.

Embodiment 9: the method of Embodiment 8, wherein the mixture Si:Al₂mole ratio is 220 to 275.

Embodiment 10: the method of any of Embodiments 1-9, wherein the mixturehas a mixture Si:Ge mole ratio of 15 to 50.

Embodiment 11: the method of any of Embodiments 1-10, wherein themixture has a mixture Na:Al mole ratio of 12 to 40.

Embodiment 12: the method of any of Embodiments 1-11, wherein thezeolite is a ZSM-5 zeolite.

Embodiment 13: the method of any of Embodiments 1-12, wherein the finalSi:Al₂ mole ratio is 125 to 200, preferably, 140 to 190, morepreferably, 151 to 189.

Embodiment 14: the method of any of Embodiments 1-13, wherein the finalcatalyst has one or both of a final Si:Ge mole ratio of 40 to 400 and afinal Na:Al mole ratio of 0.9 to 2.5.

Embodiment 15: the method of Embodiment 14, wherein the final Si:Ge moleratio is 50 to 300.

Embodiment 16: the method of any of Embodiments 14-15, wherein the Si:Gemole ratio is 80 to 200.

Embodiment 17: the method of any of Embodiments 14-16, wherein the Na:Almole ratio is 1.2 to 2.2.

Embodiment 18: the method of any of Embodiments 1-17, wherein the finalcatalyst comprises a germanium content of less than or equal to 3.0 wt%.

Embodiment 19: the method of any of Embodiments 1-18, wherein the finalcatalyst comprises one or more of a Ge content of 0.1 to 3 wt %, an Nacontent of 0.5 to 2 wt %, and a Pt content of 0.05 to 3 wt %, whereinthe wt % values are based on the total weight of the final catalystexcluding any binder and extrusion aide.

Embodiment 20: the method of Embodiment 19, wherein the Ge content is0.3 to 3, preferably, 0.4 to 2.5, more preferably, 0.6 to 1.5, even morepreferably, 0.5 to 1.5 wt %.

Embodiment 21: the method of any of Embodiments 19-20, wherein thesodium content is 1 to 2 wt %.

Embodiment 22: the method of any of Embodiments 19-21, wherein theplatinum content is 0.2 to 2, preferably, 0.2 to 1.5 wt %.

Embodiment 23: the method of any of Embodiments 1-22, wherein the methoddoes not include an ion-exchange step with an alkali metal and/or analkali earth metal.

Embodiment 24: the method of any of Embodiments 1-23, wherein the finalcatalyst is free of cesium.

Embodiment 25: the method of any of Embodiments 1-24, wherein the alkalimetal source comprises at least one of a sodium source and a potassiumsource.

Embodiment 26: the method of any of Embodiments 1-25, wherein the alkalimetal source comprises at least one of NaOH and NaCl.

Embodiment 27: the method of any of Embodiments 1-26, wherein the pH is9.5 to 12.5.

Embodiment 28: the method of any of Embodiments 1-27, wherein the pH is10 to 12.5.

Embodiment 29: the method of any of Embodiments 1-28, wherein themixture further comprises a structure directing agent.

Embodiment 30: the method of Embodiment 29, wherein the mixture has astructure directing agent to silica mole ratio of 0.01 to 1.

Embodiment 31: the method of Embodiment 30, wherein the structuredirecting agent to silica mole ratio is 0.05 to 0.5.

Embodiment 32: the method of any of Embodiments 29-31, wherein thestructure directing agent comprises TPAOH.

Embodiment 33: a catalyst prepared by any of the Embodiments 1-32.

Embodiment 34: a method of for the aromatization of hydrocarbonscomprising: contacting an alkane containing 6 to 12 carbon atoms permolecule with the catalyst of Embodiment 33 or 35 or 36.

Embodiment 35: a catalyst comprising: a zeolite comprising Si, Al, andGe in the framework with Pt deposited thereon; wherein the catalyst hasan Si:Al₂ mole ratio of greater than or equal to 125, an Si:Ge moleratio of 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5, wherein thecatalyst has an aluminum content of less than or equal to 0.75 wt %,wherein the catalyst is non-acidic.

Embodiment 36: the catalyst of Embodiment 35, wherein the Ge is presentin an amount of 0.3 to 3 wt %, and/or the Na is present in an amount of0.5 to 2 wt % and/or the Pt is present in an amount of 0.05 to 3 wt %,wherein the wt % values are based on the total weight of the finalcatalyst excluding any binder and extrusion aide.

Embodiment 37: a method for the aromatization of hydrocarbonscomprising: contacting an alkane containing 6 to 12 carbon atoms permolecule with the catalyst of any of Embodiments 33, 35, or 36.

Embodiment 38: a method for the aromatization of hydrocarbonscomprising: contacting an alkane containing 6 to 12 carbon atoms permolecule with a catalyst comprising: a zeolite comprising Si, Al, and Gein the framework with Pt deposited thereon; wherein the catalyst has anSi:Al₂ mole ratio of greater than or equal to 125, an Si:Ge mole ratioof 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5, wherein thecatalyst has an aluminum content of less than or equal to 0.75 wt %excluding any binder and extrusion aide.

Embodiment 39: the method of Embodiment 39, wherein the Ge is present inan amount of 0.3 to 3 wt %, and/or the Na is present in an amount of 0.5to 2 wt % and/or the Pt is present in an amount of 0.05 to 3 wt %,wherein the wt % values are based on the total weight of the finalcatalyst excluding any binder and extrusion aide.

In general, the invention can alternately comprise, consist of, orconsist essentially of, any appropriate components herein disclosed. Theinvention can additionally, or alternatively, be formulated so as to bedevoid, or substantially free, of any components, materials,ingredients, adjuvants or species used in the prior art compositions orthat are otherwise not necessary to the achievement of the functionand/or objectives of the present invention.

All ranges disclosed herein are inclusive of the endpoints, and theendpoints are independently combinable with each other (e.g., ranges of“up to 25 wt %, or, more preferably, 5 to 20 wt %”, is inclusive of theendpoints and all intermediate values of the ranges of “5 to 25 wt %,”etc.). “Combination” is inclusive of blends, mixtures, alloys, reactionproducts, and the like. Furthermore, the terms “first,” “second,” andthe like, herein do not denote any order, quantity, or importance, butrather are used to denote one element from another. The terms “a” and“an” and “the” herein do not denote a limitation of quantity, and are tobe construed to cover both the singular and the plural, unless otherwiseindicated herein or clearly contradicted by context. The suffix “(s)” asused herein is intended to include both the singular and the plural ofthe term that it modifies, thereby including one or more of that term(e.g., the film(s) includes one or more films). Reference throughout thespecification to “one embodiment,” “another embodiment,” “anembodiment,” and so forth, means that a particular element (e.g.,feature, structure, and/or characteristic) described in connection withthe embodiment is included in at least one embodiment described herein,and may or may not be present in other embodiments. In addition, it isto be understood that the described elements may be combined in anysuitable manner in the various embodiments.

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to Applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

Disclosure of a narrower range in addition to a broader range is not adisclaimer of the broader range.

Compounds are described using standard nomenclature. For example, anyposition not substituted by any indicated group is understood to haveits valency filled by a bond as indicated, or a hydrogen atom. A dash(“-”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, —CHO is attachedthrough carbon of the carbonyl group. In addition, it is to beunderstood that the described elements may be combined in any suitablemanner in the various embodiments.

All cited patents, patent applications, and other references areincorporated herein by reference in their entirety. However, if a termin the present application contradicts or conflicts with a term in theincorporated reference, the term from the present application takesprecedence over the conflicting term from the incorporated reference.

I/We claim:
 1. A method for making a catalyst, comprising: forming amixture comprising a germanium source, an alkali metal source, analuminum source, and a silica source, wherein the mixture has a pH;adjusting the pH of the mixture to a value of greater than or equal to9.5; crystallizing and calcining the mixture to form a zeolite;depositing platinum on the zeolite; and calcining the zeolite to formthe final catalyst; wherein the final catalyst is non-acidic and has analuminum content of less than or equal to 0.75 wt % based on the totalweight of the final catalyst excluding any binder or extrusion aide, anda final Si:Al₂ mole ratio of greater than or equal to
 125. 2. The methodof claim 1, wherein the forming of the mixture comprises: forming afirst aqueous solution, wherein the first solution comprises thegermanium source and the alkali metal source; forming a second aqueoussolution, wherein the second solution comprises the aluminum source;combining the first and second aqueous solutions to form a combinedsolution; and adding the silica source to the combined solution to formthe mixture.
 3. The method of claim 1, wherein the mixture has a mixtureSi:Al₂ mole ratio of 175 to 290, a mixture Si:Ge mole ratio of 5 to 100,and a mixture Na:Al mole ratio of 10 to
 60. 4. The method of claim 1,wherein the zeolite is a ZSM-5 zeolite.
 5. The method of claim 1,wherein the final catalyst has one or both of a final Si:Ge mole ratioof 40 to 400 and a final Na:Al mole ratio of 0.9 to 2.5.
 6. The methodof claim 1, wherein the final catalyst comprises one or more of a Gecontent of 0.1 to 3 wt %, an Na content of 0.5 to 2 wt %, and a Ptcontent of 0.05 to 3 wt %, wherein the wt % values are based on thetotal weight of the final catalyst excluding any binder and extrusionaide.
 7. The method of claim 1, wherein the method does not include anion-exchange step with an alkali metal.
 8. The method of claim 1,wherein the final catalyst is free of cesium.
 9. The method of claim 1,wherein the alkali metal source comprises at least one of a sodiumsource and a potassium source.
 10. The method of claim 1, wherein thealkali metal source comprises at least one of NaOH and NaCl.
 11. Themethod of claim 1, wherein the pH is 9.5 to 12.5.
 12. A catalystcomprising: a zeolite comprising Si, Al, and Ge in the framework with Ptdeposited thereon; wherein the catalyst has an Si:Al₂ mole ratio ofgreater than or equal to 125, an Si:Ge mole ratio of 40 to 400, and anNa:Al mole ratio of 0.9 to 2.5, wherein the catalyst has an aluminumcontent of less than or equal to 0.75 wt %, wherein the catalyst isnon-acidic.
 13. The catalyst of claim 12, wherein the Ge is present inan amount of 0.3 to 3 wt %, and/or the Na is present in an amount of 0.5to 2 wt % and/or the Pt is present in an amount of 0.05 to 3 wt %,wherein the wt % values are based on the total weight of the finalcatalyst excluding any binder and extrusion aide.
 14. A method for thearomatization of hydrocarbons comprising: contacting an alkanecontaining 6 to 12 carbon atoms per molecule with a catalyst comprising:a zeolite comprising Si, Al, and Ge in the framework with Pt depositedthereon; wherein the catalyst has an Si:Al₂ mole ratio of greater thanor equal to 125, an Si:Ge mole ratio of 40 to 400, and an Na:Al moleratio of 0.9 to 2.5, wherein the catalyst has an aluminum content ofless than or equal to 0.75 wt % excluding any binder and extrusion aide.15. The method of claim 14, wherein the Ge is present in an amount of0.3 to 3 wt %, and/or the Na is present in an amount of 0.5 to 2 wt %and/or the Pt is present in an amount of 0.05 to 3 wt %, wherein the wt% values are based on the total weight of the final catalyst excludingany binder and extrusion aide.
 16. The method of claim 1, wherein thefinal catalyst has a Ge content of 0.1 to 3 wt % based on the totalweight of the final catalyst excluding any binder and extrusion aide.17. The method of claim 1, wherein the final catalyst has a Ge contentof 0.4 to 1.5 wt % based on the total weight of the final catalystexcluding any binder and extrusion aide.
 18. The method of claim 1,wherein the final catalyst comprises Al in an amount of 0.45 to 0.7 wt %based on the total weight of the final catalyst excluding any binder andextrusion aide.
 19. The method of claim 1, wherein the final catalysthas a Ge content of 0.1 to 3 wt %, an Na content of 0.5 to 2 wt %, and aPt content of 0.05 to 3 wt %, wherein the wt % values are based on thetotal weight of the final catalyst excluding any binder and extrusionaide.
 20. The method of claim 1, wherein the final catalyst has a finalSi:Ge mole ratio of 40 to 400 and a final Na:Al mole ratio of 0.9 to2.5.